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BENDIX SD-01-700 User's Manual

1. Detroit Diesel cavity and into the other cylinder A small amount of air moves outof the inlet port On the piston down stroke TDC to BDC air flows in the reverse direction from the other cylinder through the unloader piston to the inlet cavity past the unseated unloader piston and into the cylinder bore Governor Unloader Port Air Dryer Compressor Supply Reservoir FIGURE 4 BENDIX BA 922 COMPRESSOR UNLOADER SYSTEM u Valve Air a T Closed Discharge n Port Unloader Unloader Piston Down amp Seated Piston Moving Down FIGURE 5 OPERATION LOADED INTAKE Discharge gt et Valve Unloader Air Open Port Discharge Port AZA mS SSSSSSSSE DA CTT Unloader Seated Piston Moving Up FIGURE 6 OPERATION LOADED COMPRESSION LUBRICATION The vehicle s engine provides a continuous supply of oil to the compressor Oil is routed from the engine to the compressor oil inlet An oil passage in the crankshaft conducts pressurized oll to precision sleeve main bearings and to the connecting rod bearings Spray lubrication of the cylinder bores connecting rod wrist pin bushings and ball type main bearings is obtained as oil is forced out around the crankshaft journals by engine oil pressure Oil then falls to the bottom of the compressor crankcase and is returned to the engine through dr
2. INDEX Air Air brake charging system Slow build 9 0 cece eeeeeeeceeseeeeeeeeeneees 19 20 Doesn t build air 10 0 ccccceeeseseeseeenees 21 Air dryer Doesn t purge 14 0 eiere 22 Safety valve releases air 12 0 ce 22 Compressor Constantly cycles 15 0 ereere 22 Leaks air 16 0 cceccccsssssseessessssetsaeeeeeees 23 Safety valve releases air 11 0 ce 21 NOISY T80 ciiadacacasiestnanaaiinaiauan 23 Reservoir Safety valve releases air 13 0 2an 22 1 Oil Leakage at Head Gasket 2 System Leakage 3 Compressor Discharge and Air Dryer Inlet Temperature 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader BASIC Test Information Symptom Page Number Symptom Page Number Coolant Compressor leaks coolant 17 0 Engine Oil consumption 6 0 Oil Oil Test Card results 1 0 cceeeee es Oil is present On the outside of the compressor 2 0 15 At the air dryer purge exhaust Or Surrounding area 3 0 008 In the supply reservoir 4 0 00 At the valves 5 0 c cccsesessesersseeees At air dryer cartridge 7 0 cc0000 In the ping tank or compressor discharge aftercooler 8 0 Maintenance amp Usage Guidelines Maintenance Schedule and Usage Guidelines Table A 11 Introduction to the Air Brake Charging System Powered by the vehicl
3. What you should do gt If discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 13 for recommended size and go to Test 3 on page 24 gt By other restrictions e g kinks Re place the discharge line See Table A col umn 2 on page 13 for recommended size Retest for air build Return vehicle to service or if problem persists go to 9 0 a gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a Straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Appendix B Shorter discharge line lengths or insulation may be required in cold climates Check compressor air inlet line for restric tions brittleness softor Sagging hose con ditions etc Repair as necessary Refer to vehicle manufacturer s guidelines for inlet line size Check the engine air filter and service if necessary if possible check the air filter usage indicator Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repai
4. BA 922 compressors are only permitted to be naturally aspirated use of the engine turbocharger as an air source is not allowed P late Air in Pistons Mostly Shuttles Back and Forth from One Piston to the Other During Unloaded Mode FIGURE 7 OPERATION UNLOADED Unloader Piston Up amp Unseated A supply of clean air is one of the single most important factors in compressor preventative maintenance Since the Bendix BA 922 compressor receives supply air from the engine air filter periodic maintenance of the engine air filter is necessary Inspect the compressor intake adapter and the connecting hoses each time engine air cleaner maintenance Is performed 1 Inspect the intake hose adapters for physical damage Make certain to check the adapters at both ends of the intake hose or tubing 2 Inspect the intake hose clamps and tighten them if needed 3 Inspect the intake hose or line for signs of drying cracking chafing and ruptures and replace it as necessary COMPRESSOR COOLING Inspect the compressor discharge port inlet cavity and discharge line for evidence of restrictions and carbon build up If more than 1 16 of carbon is found thoroughly clean or replace the affected parts Since carbon build up generally indicates inadequate cooling closely inspectthe compressor cooling system Check all compressor coolant lines for kinks and restrictions to flow Minimum coolant line size is 3 8 1 D
5. BENDIX BA 922 COMPRESSOR DESCRIPTION The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake systems The Bendix BA 922 compressor is a two cylinder reciprocating compressor with a rated displacement of 31 6 cubic feet per minute at 1250 RPM The compressor consists of a water cooled cylinder head cooling plate valve plate assembly and an integral air cooled crankcase and cylinder block The cast aluminum cylinder head contains the required air and water ports as well as two unloader pistons The cast aluminum cooling plate provides added cooling and is located between the cylinder head and valve plate assemblies The valve plate assembly consists of laminated brazed steel plates which incorporate various valve openings and channels for conducting air and engine coolant into and out of the cylinder head The discharge valves are part of the valve plate assembly The cylinder head with the cooling and valve plates comprise a complete cylinder head assembly The cast iron crankcase and cylinder block assembly houses the pistons connecting rods crankshaftand related bearings While not all compressors and charging systems are equipped with an optional discharge line safety valve this component is recommended The discharge line safety valve is installed in the cylinder head or close to the compressor discharge port and protects against over pressurizing th
6. Forvehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving What you should do Discontinue using this test Results Do notuse this card testto diagnose compressor oil passing issues They are subjective and error prone Use only the Bendix Air System Inspection Cup BASIC test and the methods described in this guide for advanced troubleshooting The Bendix BASIC test should be the definitive method for judging excessive oil fouling oil passing See Appendix A Bendix on page 27 for a flowchart and expanded BASIC Test explanation of the checklist used when conducting the BASIC test Symptom 2 0 Oil on the Outside of the Compressor 2 1 Oil leaking at compressor engine connections 2 2 Oil leaking from compressor 3 0 Oil at air dryer purge exhaust or surrounding area What it may indicate Engine and or other accessories leaking onto compressor a Leak at the front or rear fuel pump etc mounting flange bo Leak at air inlet fitting c Leak at air discharge fitting d Loose broken oil line fittings a Excessive leak athead gasket b Leak at bottom cover plate c Leak at internal rear flange gasket d Leak through crankcase e If unable to tell source of leak Head gaske
7. Check coolantlines for internal clogging from rust scale If coolant lines appear suspicious check the coolant flow and compare to the tabulated technical data in the back of this manual Carefully inspect the air induction system for restrictions LUBRICATION Check the external oil supply line for kinks bends or restrictions to flow Supply lines mustbe a minimum of 3 16 I D Refer to the tabulated technical data in this manual page 10 for oil pressure minimum values Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOOTING section page 11 for appropriate tests and corrective action OIL PASSING All reciprocating compressors pass a minimal amount of oil Air dyers will remove the majority of oil before it can enter the air brake system For particularly oil sensitive systems the Bendix PuraGuard system filter can be used in conjunction with a Bendix air dryer If compressor oil passing is suspected refer to the TROUBLESHOOTING section and TABLE A page 13 for the symptoms and corrective action to be taken In addition Bendix has developed the Bendix Air System Inspection Cup or BASIC kit to help substantiate suspected excessive oil passing The steps to be followed when using the 4 Unloader Coolant In or Discharge Covers Safety Valve lt p F G Inlet Port Governor Connection Discharge Port Coolant In or Out CYLINDER HEAD PORT IDE
8. The air dryer contains a filter that collects oil droplets and a desiccant bed that removes almost all of the remaining water vapor The compressed air is then passed to the air brake service Supply reservoir The oil droplets and the water collected are automatically purged when the governor reaches its cut out setting For vehicles with accessories that are sensitive to small amounts of oil we recommended installation of a Bendix PuraGuard system filter designed to minimize the amount of oil present The Air Brake Charging System supplies the compressed air for the braking system as well as other air accessories for the vehicle The system usually consists Optional Ping Tank EN Air Dryer Discharge Line ee Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor 12 of an air compressor governor discharge line air dryer and service reservoir Optional Bendix PuraGuard System Filter or PuraGuard QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Typical Discharge Recom Recom Acceptable mended mended Reservoir Line Air Dryer Reservoir Oil Contents H No of Cartridge Drain at Regular Vehicle Used for Axles Replacement Sch
9. o rings 6 8 9 in the cylinder head making certain not to damage them in the process 9 9 Install the balance piston spring 5 in the unloader piston 7 then install the small diameter of the balance piston 4 through the center of the spring 10 Install the unloader cover gasket 3 on the cylinder head making certain the unloader vent passage and both screw holes align 11 Position the unloader cover 2 on top of the balance piston 4 making certain the stamped logo is visible 12 Press and hold the unloader cover 2 in place on the cylinder head and install both unloader cover cap screws 1 Torque the cover cap screws 1 from 62 to 71 inch pounds 7 8 Nm INSTALLING THE COMPRESSOR 1 Ifthe compressor was removed for replacement install the drive components Torque the crankshaft nut to 220 254 foot pounds 210 290 Nm 2 Install any supporting bracketing on the compressor in the same position noted and marked during removal 3 Install the gasket on the drive flange of the compressor Make certain oil supply or return holes in the gasket are properly aligned with the compressor and engine Gasket sealants are not recommended Secure the compressor on the engine and tighten the mounting bolts 4 Install the discharge inletand governor adapter fittings if applicable in the same position on the compressor noted and marked during disassembly Make certain the threads are clean and the fittings are free
10. Cyclone DuraDrain water separator and the Bendix System Guard trailer air dryer are available Refer to Bendix Technical Bulletin TCH 008 042 Alcohol in the Air Brake System for additional information Air Dryers Make certain air brake system leakage is within the limits stated in BW1279 Check the operation and function of the air dryer using the appropriate Service Data Sheet for the air dryer Service Data Sheet 50 08 2403 SD 08 2407 Bendix literature is available to order or download on Bendix com m Be Appendix B Continued Technical Bulletin man Bulletin No TCH 008 022 Effective Date 1 1 1994 Page 1 of 1 nadi Subject Additional Cold Weather Operation Tips for the Air Brake System Last year we published Bulletin PRO 08 21 which provided some guidelines for winterizing a vehicle air brake system Here are some additional suggestions for making cold weather vehicle operation just a little more bearable Thawing Frozen Air Lines The old saying Prevention is the best medicine truly applies here Each year this activity accounts for an untold amount of unnecessary labor and component replacement Here are some Do s and Don ts for prevention and thawing Do s 1 Do maintain freeze prevention devices to prevent road calls Don tlet evaporators or injectors run out of methanol alcohol or protection will be degraded Check the air dryer for proper operation and change the
11. a low air use vehicle Vehicle OK m00 Return vehicle to service Bendix Air System Inspection Cup BASIC Test Information Is there YES lt 1 Vehicle OK less than one Return vehicle to END TEST unit of liquid service Cloudy emulsion mixture ah Is this vehicle being re tested after water etc was found last time YES NO Find the point on the label where the number of oil units meets the number of days x since the vehicle s air tanks R were last drained Soe ule Change air dryer Advanced rtridae Troubleshooting nade Guide to find reason s for presence of water Test for air leakage END TEST Re test with the BASIC Test after 30 days END TEST END TEST If the number of days since the air tanks were drained is unknown use the 30 day line Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles To getan accurate reading for the amountof oil collected during a 30 day period ask the customer not to drain the air tanks before returning Note that 30 90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained If in cold weather conditions the 30 day air tank drain schedule is longer than the customer s usual draining interval the customer must determine based
12. by balance piston spring 5 hold the unloader cover 2 in place while removing the two unloader cover cap screws 1 Carefully release the hold on the unloader cover until the spring force is relaxed then remove the unloader cover 2 3 Remove the unloader cover gasket 3 Remove the balance piston 4 and its spring 5 from the cylinder head 5 Remove the six hex head bolts and washers from the cylinder head 6 Remove the two bolts located in the center of the head Gently tap the head cooling plate and valve plate assembly with a soft mallet to break the gasket seal Lift the cylinder head with cooling plate and valve plate assembly off the cylinder block 7 Remove the metal reed valve gasket 12 8 Gently tap the head cooling plate and valve plate assembly with a soft mallet to break the gasket seals Then separate the cylinder head from the cooling plate and valve plate assembly and remove the gasket 11 between them 9 Turn the aluminum cylinder head over to expose the interior portion of the head Push the unloader piston 7 along with its o rings 6 8 amp 9 out of the cylinder head CRANKCASE COVER 1 Remove the four crankcase cover cap screws securing the crankcase cover to the crankcase Using a soft mallet gently tap the crankcase cover to break the gasket seal Remove the crankcase cover gasket 14 REAR END COVER OR END COVER ADAPTER 1 Remove the four end cover cap screws that secure
13. currently found when we get to step B of the test the compressor must be Q Excessive engine oil loss amount described replaced The full BASIC test below will Is the engine leaking oil Q no Q yes investigate the facts Is the compressor leaking oil LI no U yes LI Other complaint LI No customer complaint BASIC test starts here STEP A Select one The Technician selects the air use o category for the vehicle This de Q This is a low air use vehicle Line haul single trailer with 5 or less axles or cided which of the two acceptance U This is a high air use vehicle Garbage truck transit bus bulk unloader or line lines on the cup will be used for the haul with more than 5 axles Then go to Step B test below STEP B Measure the Charging System Contents Foran accurate test the 1 Park and chock vehicle on level ground Drain the air system by contents of all the air tanks on pumping the service brakes 2 Completely drain ALL the air tanks into a single BASIC cup DE veniGesnauignenscd 3 Ifthere is less than one unit of contents total end the test now and return the vehicle to service Vehicle passes Note for returning vehicles that are being 4 admore than one oil unit of water or a cloudy emulsion mixture retested after a water cloudy emulsion Is found a mixture was found last time and the air a Change the vehicle s air dryer cartridge dryer cartridge r
14. line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving REMOVAL In many instances it may not be necessary to remove the compressor from the vehicle when installing the various 0 am 0 om 6 z a z bonn Cylinder or Head l i Cooling lt s Plate 11 Valve Plate Assembly Crankcase amp Cylinder d Block A a 13 14 b 4 a crankcase NONE j i Cover Item Qty Description Item Qty Description 11 2 _ Head Gasket 1
15. not noted repair or replace the governor and or repair the compressor unloader IMPORTANT NOTE Replacement air governors must have a minimum cut in pressure of 105 psi The cut in pressure is the lowest system pressure registered in the gauges before the compressor resumes compressing air Compressors with no signal line to the unloader port should have a vent installed in the port rather than a plug SERVICE TESTS GENERAL The following compressor operating and leakage tests need not be performed on a regular basis These tests Should be performed when it is suspected that leakage is Substantially affecting compressor buildup performance or when it is suspected that the compressor Is cycling between the load and unloaded modes due to unloader plunger leakage IN SERVICE OPERATING TESTS Compressor Performance Build up Test This test is performed with the vehicle parked and the engine operating at maximum recommended governed speed Fully charge the air system to governor cut out air dryer purges Pump the service brake pedal to lower the system air pressure below 80 psi using the dash gauges As the air pressure builds back up time from when the dash air pressure gauge passes 85 to the time it passes 100 psi The time should not exceed 40 seconds If the vehicle exceeds 40 seconds testfor and fix any air leaks and then re test the compressor performance Ifthe vehicle does not pass the test the second time use the Ad
16. noticeable decrease of the dash air gauge readings repair leaks Repeat this test to confirm that air leaks have been repaired and return vehicle to service Please repeat BASIC test at next service interval Note Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary u FS ae a piles Days Since Las Ajr Tan XQ I 1 1 L I i 30 35 40 45 50 55 o 65 70 Sixty days since last air tank draining If no air leakage was detected and if you are conducting this test after completing Step C go to Step E STEP E If no air leakage was detected in Step D n Replace the compressor Note If the compressor is within warranty period please follow standard warranty procedures Attach the completed checklist to warranty claim of oil found if oil level is at or below acceptance line for number if oil level is above acceptance line gt ount 3 Action to take Y System OK eS Return to services Go to Step D umber if oil level is at or below System OK E gt 30 day acceptance line Return to services Stop inspection 0 day Test again after 30 days See Footnote 2 Decision point Air leakage is the number one cause of compressors having to pump excessive amounts of air in turn run too hot and pass oil vapor along into the system Here the Technician conducts a four minute test to see if leakage is a problem
17. of corrosion Replace as necessary See the Torque Specifications for various fitting sizes and types of thread on page 11 of this manual 5 Inspect all air oil and coolant lines and fittings before reconnecting them to the compressor Make certain o ring seals are in good or new condition Tighten all hose Clamps 6 Clean oil supply line Before connecting this line to the compressor Run the engine briefly to be sure oil is flowing freely through the supply line 7 Before returning the vehicle to service perform the Operation and Leakage Tests specified in this manual Pay particular attention to all lines reconnected during installation and check for air oll and coolant leaks at compressor connections Also check for noisy Operation TESTING REBUILT COMPRESSOR In order to properly test a compressor under operating conditions a test rack for correct mounting cooling lubricating and driving the compressor is necessary Such tests are not compulsory if the unit has been carefully rebuilt by an experienced person Acompressor efficiency or build up test can be run with realite ease An engine 10 Sequence Sequence Torque Torque FIGURE 10 BENDIX BA 922 COMPRESSOR HEAD BOLT TORQUE SEQUENCE lubricated compressor must be connected to an oil supply line of at least 15 psi pressure during the test and an oil return line must be installed to keep the crankcase drained Connectto the compressor discharge port
18. possible causes What it may indicate and remedies What you should do Review the warranty policy before performing any intrusive compressor maintenance Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty Follow all standard safety procedures when performing any maintenance WARNING Please READ and follow these instructions to avoid personal injury or death When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the ai
19. the rear end cover or end cover adapter to the crankcase 2 Remove the rear end cover or end cover adapter from the crankcase Remove the o ring seal 13 from the end cover CLEANING OF PARTS GENERAL All parts should be cleaned in a good commercial grade of solvent and dried prior to inspection CYLINDER HEAD 1 Carefully remove all gasket material adhering to the aluminum cylinder head steel valve plate assembly and cast iron cylinder block Make certain not to deeply scratch or mar the gasket surfaces Pay particular attention to the gasket surfaces of the aluminum head 2 Remove carbon deposits from the discharge and inlet cavities of the cylinder head and valve plate assembly They must be open and clear in both assemblies Make certain not to damage the aluminum head 3 Remove rust and scale from the cooling cavities and passages in the head and valve plate assembly and use shop air to clear debris from the passages 4 Check the threads in all cylinder head ports for galling Minor chasing is permitted 5 Make certain the unloader vent passage under the unloader cover 2 in the head is open and free of debris INSPECTION OF PARTS CYLINDER HEAD amp VALVE PLATE 1 Carefully inspect the cylinder head gasket surfaces for deep gouges and nicks If detected the compressor must be replaced 2 Carefully inspect the valve plate assembly gasket Surfaces for deep gouges and nicks Pay particular attention to th
20. to service Go to Test 2 on page 24 See TableA column 1 on page 13 forsome typical compressor applications If the compressor is too small for the vehicle s role forexample where a vehicle s use has changed then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty Go to Test 6 on page 25 gt An air leak at the head gasket may indi cate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing Safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a 19 20 Symptom What it may indicate 9 0 Air brake f Restricted discharge line charging system seems slow to 2 Check build pressure continued Dash gauges Kinked discharge line shown Engine Oil Quality Inadequate oil change intervals the formulation of the oil and or the quality of oil filter used can all lead to poor oil quality These can increase the rate at which carbon builds up in the discharge line Bendix recommends oil soot solids be maintained atless than 3 g Restricted air inlet not enough air to compressor Check Partly collapsed inlet line shown h Poorly filtered inlet air poor air quality to compressor Check i Compressor malfunction Check
21. with the vehicle being tested The Technician only reaches Step E if the amount of oil found for the amount of time since the air tanks were last drained exceeds the acceptance level AND the vehicle passes the four minute leakage test no noticeable leakage was detected a z Appendix B Be J Technical Bulletin s Bulletin No TCH 008 021 Effective Date 3 5 2010 Cancels PRO 08 21 dated 2 6 2008 Page 1 of 2 Subject Air Brake System Cold Weather Operation Tips As the cold weather approaches operators and fleets alike begin to look to their vehicles with an eye toward winterization and particularly what can be done to guard against air system freeze up Here are some basic Tips for operation in the cold weather Engine Idling Avoid idling the engine for long periods of time In addition to the fact that most engine manufacturers warn that long idle times are detrimental to engine life winter idling is a big factor in compressor discharge line freeze up Discharge line freeze ups account for a significant number of compressor failures each year The discharge line recommendations under Discharge Lines are important for all vehicles but are especially so when some periods of extended engine idling can not be avoided Discharge Lines The discharge line should slope downward from the compressor discharge port without forming water traps kinks or restrictions Cross overs from one side of the frame r
22. 2 1 _InletReed Valve Gasket 13 1 O Rino 14 1 Bottom Cover Gasket 10 1 __ST 4 Safety Valve Notes 1 Contained in Unloader Kit 5014473 2 Contained in Cylinder Head Gasket Kit 5014472 3 Contained in Seal Kits 5008559 5008561 5008557 amp 5008558 FIGURE 9 BENDIX BA 922 COMPRESSOR EXPLODED VIEW OF SERVICEABLE PARTS maintenance kits and service parts The maintenance 1 Block the wheels of the vehicle and drain the air technician must assess the installation and determine the pressure from all the reservoirs in the system correct course of action 2 Drain the engine cooling system and the cylinder These instructions are general and are intended to be a guide head of the compressor Identify and disconnect all In some cases additional preparations and precautions are air water and oil lines leading to the compressor necessary In all cases follow the instructions contained in 3 Remove as much road dirt and grease from the the vehicle maintenance manual in lieu of the instructions exterior of the compressor as possible precautions and procedures presented in this manual 4 Remove the discharge and inlet fittings if applicable and note their position on the compressor to aid in reassembly Note If a cylinder head maintenance kit is being installed stop here and proceed to PREPARATION FOR DISASSEMBLY If replacing the compressor continue 5 Remove any supporting bracketing attached to the compressor and note th
23. 4 Nm using a crossing pattern CYLINDER HEAD 1 Note the position of the protruding alignment pins on the cylinder block Install the metal inlet reed valve gasket 12 over the alignment pins on the cylinder block 2 Position the valve plate assembly on the cylinder block so that the alignment pins in the cylinder block fit into the corresponding holes in the valve plate assembly 3 Position and install one of the metal gaskets 11 over the alignment bushings protruding from the valve plate assembly When properly installed the outline of the gasket matches the outline of the valve plate 4 Install the cooling plate over the alignment bushings protruding from the valve plate assembly Again when properly installed the outline of the cooling plate matches the outline of the valve plate 5 Position and install the other metal gasket 11 over the alignment bushings protruding from the cooling plate assembly The outline of the gasket matches the outline of the cooling plate 6 Position and install the cylinder head over the alignment bushings protruding from the cooling plate Note The alignment bushings will only fit into two of the six cylinder head bolt holes 7 Install the two center bolts and six hex head cylinder head bolts and washers and snug them then tighten evenly to a torque of 265 to 292 inch pounds 30 33 Nm using the pattern shown in Figure 9 8 Install the unloader piston 7 with its pre installed
24. 4 Then while maintaining max rpm and are not normal vehicle conditions pressure range measure and record the Above normal temperatures can cause oil as surface temperature of the fittings vapor to pass through the air dryer into the gt atthe compressor discharge port T1 air brake system gt atthe air dryer inlet fitting T2 This testis run with the engine at normal operating Use a touch probe thermocouple for measuring temperature with engine at max rom If available the temperature a dyno may be used See table below 1 Allow the compressor to build the air system Retest before returning the vehicle to pressure to governor cut in service 2 Pump the brakes to bring the dash gauge pressure to 90 psi T1 T2 3 Allow the compressor to build pressure from Teton ae 95 to 105 psi gauge pressure and maintain Fitting Fitting this pressure range by cycling the brakes for Temperatures are within five 5 minutes normal range for this test check other symptoms Go to 4 0 h This could indicate a discharge line problem e g restriction Call 1 800 AIR BRAKE 1 800 247 2725 and speak with our Tech Team Compressor is running hot Check coolant 4 f and or Discharge Line discharge line 4 g Tests continued Test 4 Governor Malfunction Inspect control lines to and from the governor for restrictions e g collapsed or kinked Repair as necessary Using a calibrated external gauge in the Test 5 Gover
25. NTIFICATION The cylinder head connection ports are identified with cast in numerals as follows Atmospheric AIR IN 0 Compressed AIR OUT 21 Coolant IN or OUT 91 and 92 Governor Control 41 Compressors with no signal line to the unloader port should have a vent installed in the port rather than a plug FIGURE 8 TYPICAL BA 922 COMPRESSOR CYLINDER HEAD BASIC kit are presented in APPENDIX A at the end of the TROUBLESHOOTING section COMPRESSOR DRIVE Check for noisy compressor operation which could indicate excessive drive component wear Adjust and or replace as necessary Check all compressor mounting bolts and retighten evenly if necessary Check for leakage and proper unloader mechanism operation Repair or replace parts as necessary COMPRESSOR UNLOADER amp GOVERNOR Test and inspect the compressor and governor unloader system for proper operation and pressure setting 1 Check for leakage atthe unloader port Replace leaking Or worn o ring 2 Make certain the unloader system lines are connected as illustrated in Figure 3 3 Cycle the compressor through the loaded and unloaded cycle several times Make certain thatthe governor cuts in compressor resumes Compressing air ata minimum of 105 psi cut out should be approximately 15 20 psi greater than cut in pressure Adjust or replace the governor as required 4 Note that the compressor cycles to the loaded and unloaded conditions promptly If prompt action is
26. These items prevent the weight of ice and snow accumulations from breaking or disconnecting air lines and wires Automatic Drain Valves System without Air Dryer As we Stated last year routine reservoir draining is the most basic step although not completely effective in reducing the possibility of freeze up While automatic drain valves relieve the operator of draining reservoirs on a daily basis these valves MUST be routinely checked for proper operation Don t overlook them until they fail and a road call is required 31 BW2398 2010 Bendix C i ommercial Vehicle Syst ystems LLC a member of the Knorr Bremse Group All rights reserved 11 2010 amp Printed on recycled paper 32
27. a reservoir with a volume of 1500 cubic inches including the volume of the connecting line With the compressor operating at 2100 RPM the time required to raise the reservoir s pressure from 85 psi to 100 psi should notexceed 5 seconds During this test the compressor should be checked for gasket leakage and noisy operation as well as unloader operation and leakage If the compressor functions as indicated reinstall on the vehicle connecting all lines as marked in the disassembly procedure BENDIX BA 922 COMPRESSOR SPECIFICATIONS OG A WV SIN E E E maa A T 60 Ibs NUMBER OT CVINGETS scindarsteietnanseveria manana 2 Bore Diameter siscivetiiiiiiminenstinns 3 622 in 92 005 mm Stroke ssirsiursincvvinrsrverhaetisriieaiideinermainas 2 125 in 53 970 mm Calculated displacement at 1250 RPM eese 31 7 CFM Flow Capacity 1800 RPM amp 120 PSl 25 2 CFM Flow Capacity 3000 RPM amp 120 PSl 38 4 CFM Maximum recommended RPM eessen 3000 RPM Minimum coolant flow maximum RPM nan 2 0 Gals Min Approximate horsepower required Loaded 1800 RPM at 120 PSIG essere 8 73 HP Unloaded 1800 RPM sssssesessssssrrrsrsresssrsrrrrrrrreesrsrerrrrn 1 96 HP Maximum inlet air temperature cccceseccesseeeeeeeeseaeeeeees 170 F Maximum discharge air temperature ccceeceeeeeeeeeeeeeeees 350 F Minimum oil pressure required sssssrrseererrrrerrerrrrrrren 15 PSI Minimum oil supply line Size eesseeesssrreeerrrrrrrrn 3 16 I D Minim
28. ail to the other if required should occur as close as possible to the compressor Dryer Inlet Temperature The dryer inlet air temperature should typically be within the range of no more than 160 F and no less than 45 F above low ambient Surrounding temperature to prevent freeze ups For example if low ambient is minus 40 F the dryer inlet must be above 5 F Lower dryer inlet temperatures should be avoided to minimize the risk of freeze up upstream of the air dryer Higher temperatures should also be avoided to minimize the risk of heat damage to the air dryer seals and to avoid a loss of drying performance Compressor Line Size The line size and length is established by the vehicle manufacturer and should not be altered without the vehicle manufacturers approval As a reference the line length from the compressor to the air dryer should be less than 16 feet and the minimum line sizes should be as follows Minimum ere Length Minimum application Low Compressor Duty Cycle Applications 0 20 10 ft High Compressor Duty Cycle Applications 20 40 Line Insulation To guard against freez ups in Low Duty Cycle applications the discharge line can be insulated if it is greater than 9 feet in length The line can only be insulated back to 9 feet and a maximum of 3 feet For example if the line is 10 feet insulate the fitting and the last one foot of the line If the line is 15 feet insulate the fitting and the last 3 feet of th
29. ain holes in the compressor mounting flange Unloader Piston Up amp Unseated Air Inlet Port Air From Governor Unloader Port Valve COOLING Air flowing through the engine compartment from the action of the engine fan and the movement of the vehicle assists in cooling the compressor Cooling fins are part of the crankcase cylinder block casting Coolant flowing from the engine cooling system through connecting lines enters the head and passes through internal passages in the cylinder head and valve plate assembly and Is returned to the engine Proper cooling is important in minimizing discharge air temperatures Figure 8 illustrates the coolant flow connections See the tabulated technical data in the back of this manual for specific requirements PREVENTATIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Refer to Table A in the Troubleshooting section for a guide to various considerations that must be given to maintenance of the compressor and other related charging system components Important Note Review the warranty policy before performing any intrusive maintenance procedures An extended warranty may be voided if intrusive maintenance is performed during this period EVERY 6 MONTHS 1800 OPERATING HOURS OR AFTER EACH 50 000 MILES WHICHEVER OCCURS FIRST PERFORM THE FOLLOWING INSPECTIONS AND TESTS AIR INDUCTION Bendix
30. damage compressor and is not covered under warranty Check Go to Test 4 on page 25 If you found excessive oil present in the service reservoir in step 4 0 b above and you did not find any Issues in steps 4 0 c through 4 0 j above the compressor may be passing oil Replace compressor If still under warranty follow normal warranty process Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member 5 0 Oil present at valves e g at exhaust or seen during servicing Air brake system valves are required to tolerate a light coating of oil Y Normal Genuine Bendix valves are all SAE J 2024 compliant gt A small amount of oil does not affect SAE J 2024 compliant valves gt Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the accept able range shown on the Bendix BASIC test cup see also column 5 of Table A on page 13 Return the vehicle to service For oil Sensitive systems see page 12 SAE J 2024 outlines tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination Symptom 6 0 Excessive oi
31. desiccant when needed 2 Do thaw out frozen air lines and valves by placing the vehicle in a warmed building This is the only method for thawing that will not cause damage to the air system or its components 3 Do use dummy hose couplings on the tractor and trailer 4 Do check for sections of air line that could form water traps Look for drooping lines Don ts 1 Do not apply an open flame to air lines and valves Beyond causing damage to the internal nonmetallic parts of valves and melting or burning non metallic air lines WARNING THIS PRACTICE IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids poured into the system wash lubricants out of valves collect in brake chambers and valves and can cause malfunction Loss of lubricant can affect valve operating characteristics accelerate wear and cause premature replacement 3 Do not park a vehicle outside after thawing its air system indoors Condensation will form in the system and freeze again Place the vehicle in operation when it is removed to the outdoors Supporting Air and Electrical Lines Make certain tie wraps are replaced and support brackets are re assembled if removed during routine maintenance
32. discharge line lengths or insulation may be required in cold climates Check compressor air inlet line for restric tions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water Check the engine air filter and service if necessary if possible check the air filter usage indicator Check If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member 17 18 Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued Crankcase Flooding Consider installing a compressor bottom drain kit where available in cases of chronic oil passing where all other operating conditions have been investigated What it may indicate Other cont 1 Poorly filtered inlet air poor air quality to compressor Inspect the engine air cleaner j Governor malfunction or setting k Compressor malfunction Bendix compressors are designed to have a dry Sump and the presence of excess oil in the crankcase can lead to oil carryover What you should do gt Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirtingestion will
33. e parking brakes may have to be released and or spring brakes caged and this will require that the vehicle be prevented from moving by other means for the duration of these tests procedures 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or
34. e compressor in the event of a discharge line freeze up or blockage OPERATION The compressor is driven by the vehicle engine and functions continuously while the engine is in operation Actual compression of air is controlled by the compressor unloading mechanism operating in conjunction with a governor SD 01 700 Cylinder Valve Plate Assembly Crankcase and Cylinder Block FIGURE 1 BENDIX BA 922 COMPRESSOR Delivery Air Unloader 2 Port Intake a _ a Unloader J Port T RX Bp ee Cooling wE Discharge a Reed Valves TEE d 4 D P late Piston Piston Rod Crankshaft FIGURE 2 BENDIX BA 922 COMPRESSOR CUT AWAY Detroit illar Caterpilla Diesel FIGURE 3 TYPICAL COMPRESSOR DRIVE FLANGES AIR INTAKE LOADED During the piston down stroke a vacuum is created in the cylinder bore above the piston The vacuum causes the inlet reed valve to flex open Atmospheric air flows through the open inlet valve and fills the cylinder bore above the piston AIR COMPRESSION LOADED When the piston reaches approximately bottom dead center BDC the inlet reed va
35. e engine the air compressor builds the air pressure for the air brake system The air compressor is typically cooled by the engine coolantsystem and lubricated by the engine oil supply The compressor s unloader mechanism and governor along with a synchro valve for the Bendix DuraF lo 596 air compressor control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service or supply reservoir When the air pressure becomes greater than that of the preset cut out the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also causes the air dryer to purge As the service reservoir air pressure drops to the cut in setting of the governor the governor returns the compressor back to building air and the air dryer to air drying mode As the atmospheric air is compressed all the water vapor Originally in the air is carried along into the air system as well as a Small amount of the lubricating oil as vapor The duty cycle is the ratio of time the compressor Spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance F actors that add to the duty cycle are air suspension additional air accessories use of an
36. e line 29 30 Appendix B Continued Bulletin No TCH 008 021 Effective Date 3 5 2010 Page 2 of 2 System Leakage Check the air brake system for excessive air leakage using the Bendix Dual System Air Brake Test and Check List BW1279 Excessive system leakage causes the compressor to pump more air and also reduce the life of the air dryer desiccant cartridge Reservoir Draining System without an Air Dryer Routine reservoir draining is the most basic step in reducing the possibility of freeze up All reservoirs in a brake system can accumulate water and other contamination and must be drained The best practice is to drain all reservoirs daily if the air brake system does not include an air dryer When draining reservoirs turn the ENGINE OFF and drain ALL AIR from the reservoir better still open the drain cocks on all reservoirs and leave them open over night to assure all contamination is drained reference Service Data Sheet SD 04 400 for Bendix Reservoirs If automatic drain valves are installed check their operation before the weather turns cold reference Service Data Sheet SD 03 2501 for Bendix DV 2 Automatic Drain Valves It should be noted that while the need for daily reservoir draining is eliminated through the use of an automatic drain valve periodic manual draining is still required Reservoir Draining System with an Air Dryer Daily reservoir draining should not be performed on systems with an air d
37. e metal gasket surface A metal gasket 12 is used between the valve plate assembly and the cylinder block This surface must be smooth and free of all but the most minor scratching If excessive marring or gouging is detected the compressor must be replaced 3 Inspect the cylinder head for cracks or damage With the cylinder head and head gasket secured to the valve plate assembly apply shop air pressure to one of the coolant ports with all others plugged and check for leakage by applying a soap solution to the exterior of the head If leakage is detected in the cylinder head casting replace the compressor END COVER OR END COVER ADAPTER Check for cracks and external damage Check the crankshaft main bearing surface in the end cover or end cover adapter check for excessive wear and flat spots and replace the end cover if necessary Check for galling of the oil port threads and replace the end cover or end cover adapter if necessary Minor thread chasing is permitted but do not recut the threads if they are badly damaged CYLINDER BLOCK 1 Check the cylinder head gasket surface on the cylinder block for nicks gouges and marring A metal gasket is used to seal the cylinder head to the cylinder block This surface must be smooth and free of all but the most minor scratching If excessive marring or gouging Is detected the compressor must be replaced DISCHARGE LINE 1 Inspectthe discharge line for kinks damage or carbo
38. ed for a very short time What it may indicate a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air dryer maintenance not performed d Air dryer malfunction e Improper governor control line installation to the reservoir f Governor malfunction a Reservoir safety valve malfunction ob Governor malfunction c Compressor unloader mechanism malfunction a Air dryer malfunction 0 Governor malfunction c Air brake system leakage d Improper governor control line installation to the reservoir a Air brake charging system maintenance not performed Check 6 Compressor unloader mechanism malfunction c Air dryer purge valve or delivery check valve malfunction d Air brake system leakage What you should do Inspect delivery lines to reservoir for restric tions and repair as needed Verify relief pressure is at vehicle or component manufacturer specifications Replace if defective See Maintenance Schedule and Usage Guidelines Table A column 3 on page 13 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 5 on page 25 Go to Test 4 on page 25 Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective Go to Test 4 on page 25 Go to Test 6 on page 25 Verify o
39. edule Drain Interval Low Air Use ee with less than 15 duty BASIC test e g Line haul single trailer For oil carry over a as w o air suspension air over ore eae Recom fea hydraulic brakes less he l mended 3 oil units E 5 8 in 9ft Every 3 Every per month Years Month ee Compressor with up to 25 duty cycle Max of appendix e g Line haul single trailer 5 every 90 A with air suspension RV or For oll carry over days hool bus control suggested ee ESS upgrades a asl 5 8 in 12 ft For the Bendix Tu Flo 550 air compressor Bendix BA 921 air compressor pick up amp delivery a or terminal jockey off highway construction loggers concrete mixer a truck fire truck 5 8 in Bendix Tu Flo 750 air compressor High Air Use e g Double triple trailer open highway coach most Compressor with up to 25 duty cycle e g City transit bus refuse urban region coach central tire inflation a A bape y bulk unloaders low boys bovi A Bendix BA 922 or DuraFlo 596 air compressor Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often 2 Use the drain valves to slowly drain all reservoirs to zero psi 3 Allow the oil water mixture to fully settle before measuring oil quantity 4 To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing upstream in the air system replace the disc
40. eir positions on the compressor to aid in reassembly 6 Remove the flange mounting bolts and remove the compressor from the vehicle 7 Inspect gear and associated drive parts for visible wear or damage Since these parts are precision fitted they must be replaced if they are worn or damaged If replacing the compressor or replacing the drive gear remove the drive gear from the compressor crankshaft using a gear puller 8 If the compressor is being replaced stop here and proceed to Installing The Compressor at the end of the assembly procedure PREPARATION FOR DISASSEMBLY Remove the balance of road dirt and grease from the exterior of the compressor with a cleaning solvent Mark the rear end cover or end cover adapter in relation to the crankcase It is recommended but not specifically necessary to mark the relationships of the cylinder head cooling plate valve plate assembly crankcase and cylinder block assembly A convenient method to indicate the above relationships is to use a metal scribe to mark the parts with numbers or lines Do not use marking methods such as chalk that can be wiped off or obliterated during rebuilding Prior to disassembly make certain that the appropriate kits and or replacement parts are available Refer to Figure 9 during the entire disassembly and assembly procedure CYLINDER HEAD 1 Remove the discharge safety valve 10 from the cylinder head 2 To restrain the spring force exerted
41. eplaced If more than see Footnote 1 ane ani b Conduct the 4 minute leakage test Step D c STOP the inspection and check the vehicle again after 30 days see Footnote 2 as CIE go to Step C Footnote 1 Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles Footnote 2 To al accurate reading for the amount of oil collected during a 30 day period ask the customer not to drain the air tanks before returning Note that 30 90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained If in cold weather conditions the 30 day air tank drain schedule is longer than the customer s usual draining interval the customer must determine based on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 021 and TCH 008 022 included in Appendix B of the advanced troubleshooting guide one oil unit of water or a cloudy emulsion mixture is found again stop the BASIC test and consultthe air dryer s Service Data sheet troubleshooting section 27 28 Appendix A continued Information about the BASIC Test kit Bendix P N 5013711 Filling in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dry
42. er STEP C How to Use the BASIC Test The Technician uses the chart label on the BASIC test cup to help decide the action to take based on the amount of oil found Use the lower acceptance line for low air use vehicles and upper line for high air use vehicles from Step A 2 Record am 1 Record days since air tanks were last drained If number of days is 30 60 days high air use or 30 90 days low air use gt of days gt acceptance line for n of days gt Otherwise gt if the number of days is unknown or outside the limits above if oil level is above 3 BASIC Test Example An oil level of 4 units in a sixty day period is within the acceptance area ator below the line for both low and high air use vehicles Return the vehicle to service The Technician looks for the point where the number of days since the air tanks were drained meets the oil level If itis at or below the low or high use acceptance line the vehicle has passed the test If the point is above the line then go to the leakage test STEP D Air Brake System Leakage Test n Park the vehicle on level ground and chock wheels Build system pressure to governor cut out and allow the pressure to stabilize for one minute 1 Observe the dash gauges for two additional minutes without the service brakes applied 2 Apply service brakes for two minutes allow pressure to stabilize and observe the dash gauges If you see any
43. er records info including the number of days since all air tanks were drained and fills out symptom checklist Technician inspects items START BASIC TEST Park vehicle on LEVEL ground Chock wheels drain air from system g Drain contents of ALL air tanks into BASIC cup NO Is there more than one unit of e water or e cloudy emulsion mixture NO only oil Is this a transit vehicle bulk unloader or has more than 5 axles YES this is a high air use vehicle Find the point on the label where the number of oil units meets the number of days were last drained Is the point above the HIGH Air Use line on the Is the point above the LOW Air Use line on the cup Use Test 2 Air Leakage Repair leaks and the vehicle have excessive air leakage END TEST return vehicle to service NO NO did not know when last l drained Re test with the BASIC Test after 30 days Was the number of days since last draining known YES number of days was known 30 90 days Replace the Compressor If under warranty follow standard procedures If after a compressor was already replaced the vehicle fails the BASIC test again do not replace the compressor use the Advanced Troubleshooting Guide to investigate the cause s END TEST END TEST YES H0 NO this is
44. harge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not covered under warranty Note To help prevent discharge line freeze ups shorter discharge line Test Kit Order Bendix P N 5013711 Every 2 For oil carry over Years control suggested upgrades Ie SE BASIC test acceptable range Every 5 oil units Month per month See appendix 3 4 in 12 ft A Every Year BASIC Bulletins TCH 008 021 and TCH 008 022 included in Appendix B for more information For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible Note Compressor and or air dryer upgrades are recommended in cases where duty cycle is greater than the normal range for the examples above For correct compressor upgrades consult Bendix Please note that because a compressor is listed in the same area of the chart does not necessarily mean that it would be a suitable candidate for upgrade purposes lengths or insulation may be required in cold climates See Bendix For Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles 13 Air Brake Charging System Troubleshooting How to use this guide Find the symptom s that you see then move to the right to find the
45. l consumption in engine 7 0 Oil present at air dryer cartridge during maintenance 8 0 Oil in ping tank or compressor dis charge aftercooler 9 0 Air brake charging system seems slow to build pressure What it may indicate A problem with engine or other engine accessory The engine service manual has more information Air brake charging system is functioning ee Y Normal Oil shown leaking from an air dryer cartridge Airbrake charging system is functioning normally Y Y Normal a Air brake charging system functioning normally Y Normal bo Air brake system leakage c Compressor may be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket What you should do gt See engine service manual Check Air dryers remove water and oil from the air brake charging system A small amount of oil is normal Check that regular maintenance is being performed and that the amountof oil in the airtanks reservoirs is within the acceptable range shown by the BASIC Test see also column 5 of Table A on page 13 Replace the air dryer cartridge as needed and return the vehicle to service Follow vehicle O E maintenance recommendation for these components Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rom Return the vehicle
46. lve closes Air above the piston Is trapped by the closed inlet reed valve and is compressed as the piston begins to move toward top dead center TDC When air in the cylinder bore reaches a pressure greater than that of the system pressure the discharge reed valves open and air flows into the discharge line and air brake system Air during the compression stroke flows into the hollow center of the unloader piston through an opening in the end of the piston Compressed air acts on the interior surfaces of the unloader piston and along with the unloader piston Spring holds the unloader piston against its seat on the valve plate See Figure 6 NON COMPRESSION OF AIR UNLOADED When air pressure in the supply reservoir reaches the cut out setting of the governor the governor delivers system air to the compressor unloader port Air entering the unloader port acts on the unloader piston causing it to move away from its seat on the valve plate assembly When the unloader piston is unseated a passage Is opened between the cylinder bore the air inlet cavity in the cylinder head and the other cylinder Air compression ceases See Figure 7 As the piston moves from bottom dead center BDC to top dead center TDC air in the cylinder bore flows past the unseated unloader piston into the cylinder head inlet 2
47. mixture is present change the vehicle s air dryer check for air system leakage Test 2 on page 24 stop inspection and check again at the next service interval See the BASIC test kit for full details If less than one oil unit of water or water cloudy emulsion mixture is present use the BASIC cup chart on the label of the cup to determine if the amountof oil found is within the acceptable level gt If within the normal range return the vehicle to service For vehicles with acces sories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter gt If outside the normal range go to Symp tom 4 0 c Also see the Table A on page 13 column 3 for recommended air dryer cartridge replacement schedule Go to Test 2 on page 24 See Table A column 1 on page 13 for recommended compressor sizes gt If the compressor is too small for the vehicle s role for example where a vehicle s use has changed or service condi tions exceed the original vehicle or engine OE spec s then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty gt Ifthe compressor is correct for the vehicle go to Symptom 4 0 e Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued Testing the temperature at the discharge fitting What it may indicate Tem
48. n deposits Replace as necessary See the advanced troubleshooting guide for more information ASSEMBLY General Note All torques specified in this manual are assembly torques and typically can be expected to fall off after assembly is accomplished Do not re torque after initial assembly torques fall unless instructed otherwise A compiled listing of torque specifications is presented on page 11 of this manual INCH POUNDS TO FOOT POUNDS To convert inch pounds to foot pounds of torque divide inch pounds by 12 12 Inch Pounds _ 1 Foot Pound 12 Example FOOT POUNDS TO INCH POUNDS To convert foot pounds to inch pounds of torque multiply foot pounds by 12 Example 1FootPound x 12 12 Inch Pounds CRANKCASE COVER 1 Position the crankcase cover gasket 14 on either the crankcase or crankcase cover and install the crankcase cover on the crankcase using the four cap screws Snug the four cap screws then torque to 62 71 inch pounds 7 8 Nm using a crossing pattern CRANKCASE END COVER OR ADAPTER 1 Install the end cover o ring 13 on the crankcase end cover 2 Orientthe crankcase end cover or end cover adapter to the crankcase using the reference marks made during disassembly Carefully install the end cover or end cover adapter in the crankcase making certain not to damage the crankshaft bearing surface in it 3 Install the four end cover screws or studs Snug the screws then tighten to 195 to 213 inch pounds 22 2
49. nce kit available from authorized Bendix parts outlets COMPRESSOR REMOVAL amp DISASSEMBLY GENERAL The following disassembly and assembly procedure is presented for reference purposes and presupposes that a rebuild or repair of the compressor Is being undertaken Several maintenance kits are available The instructions provided with these parts and kits should be followed in lieu of the instructions presented here MAINTENANCE KITS amp SERVICE PARTS Cylinder Head Gasket Kit ccccsseeseeeeessseeeeeeeeees 5014472 Unbader KiE eaeoe eE EE ERER 5014473 Governor Adapter Kit esssssssssesssrrrrrresrrrrrrrrresrrrrrens 5008561 Compressor Seal Kit crankcase 5008559 CAT MD Col 6 arene arr ee me ee eee mere ee 5012367 CAT AD Sealk cae ae mee eran ne 5012369 Series 60 Seal Kil ricsnecismenccieneraeeneemns erase 5012371 ST 4 Discharge Safety Valve 7 8 14 thrd 801116 ST 4 Discharge Safety Valve M16 1 5 thrd 800534 All components shown in Figure 10 with a key number are available in kits and or as individual service parts GENERAL SAFETY GUIDELINES WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Where specifically directed th
50. nor Control Line 1 Ensure that the governor control line from the reservoir is located at or near the top of the reservoir This line if located near the bottom of the reservoir can become blocked or restricted by the reservoir contents e g water or ice Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock wheels and follow all standard safety procedures Remove the governor and install a fitting to the unloader port Add a section of air hose min 1 ft long for a 1 2 diameter line and a gauge to the fitting followed by a shut off valve and an air source Shop air or small air tank Open the Supply reservoir service reservoir or reservoir port of the D 2 governor verify cut in and cut out pressures are within vehicle OEM specification If the governor is malfunctioning replace it Perform proper reservoir drain intervals and air dryer cartridge maintenance per Maintenance Schedule and Usage Guidelines Table A on page 13 Return the vehicle to service shut off and charge the unloader port by allowing air pressure to enter the hose and unload the compressor Shut off the air supply and observe the gauge A steady reading indicates no leakage at the unloader port but a falling reading shows thatthe unloader mechanism Is leaking and needs to be serviced 25 26 ee the vehicle s air tanks Appendix A Information about the BASIC Test kit Bendix P N 5013711 Service writ
51. on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 021 and TCH 008 022 included on pages 30 32 of this document N ote After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system Appendix A continued Information about the BASIC Test kit Bendix P N 5013711 Filling in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dryer The Service Writer fills out these fields with information gained from the customer No ofAxles _ Checklist for Technician Customer s Have you confirmed e k all th y l ADE pii y The Technician l Relay valve Q leaks oil Q malfunctions LI no U yes specks Waves The Service Writer Dash valve Q leaks oil Q malfunctions Ono O yes eth also checks off any 2 Air dryer leaks oil O no O yes arany OEMS complaints that the Q Governor malfunction UO no Q yes complaints that customer makes to O Oil in gladhands LI no U yes can be confirmed help the Technician how much oil did you find l 7 ae Q Oil on ground or vehicle exterior gating rane amount described O Short air dryer cartridge life replaces every 0 miles O kms or Q months x Note A confirmed complaint above does NOT mean that We will measure amount
52. peration of air dryer Follow vehicle O E maintenance recommendations Go to Test 4 on page 25 Go to Test 2 on page 24 Go to Test 5 on page 25 Available reservoir capacity may be re duced by build up of water etc Drain and perform routine maintenance per Table A columns 3 amp 4 on page 13 Go to Test 6 on page 25 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 2 on page 24 Symptom 16 0 Compressor leaks air th gt 2 p a a Testing for leaks with soap solution 17 0 Compressor leaks coolant 18 0 Noisy compressor Multi cylinder compressors only This guide attempts to cover most com pressor system problems Here are some rare sources of problems not covered in this guide e Turbocharger leakage Lubricating oil from leaking turbocharger seals can enter the air compressor intake and give mis leading symptoms What it may indicate a Compressor leaks airatconnections or ports o Compressor unloader mechanism malfunction c Damaged compressor head gasket s Head gaskets a locations a Improperly installed plugs or coolant line fittings ob Damaged compressor head gasket c Porous compressor head casting a Damaged compressor What you should do gt Check for leaking damaged or defective compressor fittings gaskets etc Repair or replace as nece
53. perature e Air compressor discharge and or air dryer inlet temperature too high f Insufficient coolant flow Inspecting the coolant hoses g Restricted discharge line Kinked discharge line shown Other h Restricted air inlet not enough air to compressor Partly collapsed inlet line shown What you should do gt Check temperature as outlined in Test 3 on page 24 If temperatures are normal go to 4 0 h gt Inspect coolantline Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary gt Verify coolant lines go from engine block to compressor and back to the water pump Repair as necessary gt If discharge line is restricted or more than 1 16 carbon build up is found replace the discharge line See Table A column 2 on page 13 for recommended size Replace as necessary gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a Straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Appendix B Shorter
54. r inlet components as needed Note Dirtingestion willdamage compressor and is not covered under warranty Replace the compressor only after making certain thatnone of the preceding conditions 9 0 a through 9 0 h exist Symptom What it may indicate 10 0 Air charging a Governor malfunction system doesn t build air b Restricted discharge line c Air dryer heater malfunction exhaust port frozen open d Compressor malfunction Note For the Bendix DuraF lo 596 air compressor not only the governor but also the SV 1 synchro valve used would need to be tested See Bulletin TCH 001 048 a Restricted discharge line Check 11 0 Compressor safety valve releases air Compressor builds too much air Damaged discharge line shown b Downstream air brake system check valves or lines may be blocked or damaged c Air dryer lines incorrectly installed d Compressor safety valve malfunction e Compressor unloader mechanism malfunction f Governor malfunction What you should do Go to Test 4 on page 25 gt See 9 0 f gt Replace air dryer heater gt Replace the compressor only after making certain the preceding conditions do not exist gt If discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 13 for recommended size and go to Test 3 on page 24 gt By other restric
55. r pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system ora dryer reservoir module be sure to drain the purge reservoir Symptom What it may indicate 1 0 Oil Test Card Nota valid test Look for Y Y Normal Normal Charging system is working within normal range Check Check Charging system needs further investigation Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts Should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically Stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper Operating condition
56. ryer This practice will cause the dryer to do excessive work i e build pressure from 0 130 psi instead of the normal 110 130 psi Alcohol Evaporator or Injector Systems Bendix Commercial Vehicle Systems LLC discourages the use of alcohol in the air brake system as a means of preventing system freeze up in cold temperatures Studies indicate that using alcohol and alcohol based products sold for this purpose removes the lubrication from the components of the air braking system In addition the materials used for the internal seals of the air system components may be adversely impacted by the residue that some anti freeze additives leave behind Both are detrimental to air system component life expectancy causing premature wear Because of this Bendix air system components warranty will be void if analysis shows that alcohol was added to the air brake system Alcohol is not an acceptable substitute for having adequate air drying capacity If the air dryer is maintained in accordance with the manufacturer s recommended practices and moisture is found to be present in the system reservoirs more drying capacity is required Bendix has several viable options including extended purge air dryers extended purge tandem dryers in parallel with common control and air dryers arranged to provide continuous flow as with the Bendix EverFlow continuous flow air dryer module To address concerns with contaminants in trailer air brake systems the Bendix
57. s have not been drained per the schedule in Table A on page 13 Column 4 and or the air dryer maintenance has not been performed as in Column 3 bo If the vehicle maintenance has been performed as recommended in Table A on page 13 some oil in the reservoirs is normal Drain all air tanks reservoirs into the Bendix BASIC test cup Bendix kit P N 5013711 Duty cycle too high c Air brake system leakage d Compressor may be undersized for the application The duty cycle is the ratio of time the compressor spends building air to total engine running time Air compressors are designed to build air to run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc What you should do gt Drainallairtanks and check vehicle atnext service interval using the Bendix BASIC test See Table A on page 13 column 3 and 4 for recommended service schedule Check Drain all air tanks into Bendix BASIC test cup Bendix Air System Inspection Cup If less than one unit of reservoir contents is found the vehicle can be returned to service Note If more than one oil unit of water or a cloudy emulsion
58. ssary gt Go to Test 6 on page 25 gt An air leak at the head gasket s may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a gt Inspect for loose or over torqued fittings R eseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor gt Anairleak atthe head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do notre use the Safety valve withouttesting SeeSymptom 12 0 a gt If casting porosity is detected replace the compressor gt Replace the compressor Other Miscellaneous Areas to Consider e Where a compressor does not have a safety valve installed if a partial or complete discharge line blockage has occurred damage can occur to the con necting rod bearings Damage of this kind may not be detected and could lead to compressor problems ata later date 23 Tests Test 1 Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system Oil
59. tions e g kinks Replace the discharge line See Table A column 2 on page 13 for recommended size gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If Instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a Straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Appendix B Shorter discharge line lengths or insulation may be required in cold climates gt Inspectair lines and verify check valves are operating properly gt Ensure discharge line is installed into the inlet of the air dryer and delivery is routed to the service reservoir gt Verify relief pressure Is 250 psi Replace if defective gt Go to Test 6 on page 25 Go to Test 4 on page 25 21 Symptom 12 0 Air dryer safety valve releases air Air dryer safety valve f _ P J n i Tj Tiet A n i 4 i E N FE E i sk a r Ba 4 rik rf i Ma q 5 x B p ER ii P E j a Fa A A Technician removes governor 13 0 Reservoir safety valve releases air 14 0 Air dryer doesn t purge Never hear exhaust from air dryer 15 0 Compressor constantly cycles compressor remains unload
60. ts and rear flange gasket locations Air brake charging system functioning normally Y Normal What you should do Find the source and repair Return the vehicle to service Repair or replace as necessary If the mounting bolt torques are low replace the gasket Replace the fitting gasket Inspect inlet hose and replace as necessary Replace gasket or fitting as necessary to ensure good seal Inspect and repair as necessary Go to Test 1 on page 24 Reseal bottom cover plate using RTV Silicone sealant Replace compressor Replace compressor Clean compressor and check periodically Check Air dryers remove water and oil from the air brake charging system Check that regular maintenance is being performed Return the vehicle to service An optional kit Bendix piece number 5011327 for the Bendix AD IS or AD IP air dryers or 5003838 for the Bendix AD 9 air dryer is available to redirect the air dryer exhaust 16 Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member if See Table A on page 13 for maintenance schedule information What it may indicate Maintenance a If air brake charging system mainte nance has not been performed Thatis reservoir
61. uld not exceed 50 sccm 4 Apply 120 130 psi shop air pressure to the discharge portand then apply and release air pressure to the inlet port Soap the inlet port and note that leakage at the inlet port does not exceed 20 sccm If excessive leakage is noted in tests 3 or 4 replace or repair the compressor using genuine Bendix replacements or maintenance kits available from any authorized Bendix parts outlet While itis possible to test for inlet discharge and unloader piston leakage It may not be practical to do so Inlet and discharge valve leakage can generally be detected by longer compressor build up and recovery times Compare Current compressor build up times with the last several recorded times Make certain to test for air system leakage as described above before making a determination that compressor performance has been lost Unloader leakage is exhibited by excessive compressor cycling between the loaded and unloaded condition 1 With service and supply system leakage below the maximum allowable limits and the vehicle parked bring system pressure to governor cut out and allow the engine to idle 2 The compressor should remain unloaded fora minimum of 5 10 minutes If compressor cycling occurs more frequently and service and supply system leakage is within tolerance including any leakage that may be present at the air dryer exhaust replace or repair the compressor unloader system using a genuine Bendix maintena
62. um unloader line SIZE ccccsssseeeeeeeeeseeeeeeeseees 3 16 I D Minimum Governor Cut Out P reSSuUre sesser 120 PSI TORQUE SPECIFICATIONS Assembly Torques in inch pounds in Ibs M8x1 25 6g Cylinder Head 265 292 In Lbs 30 33 Nm M5x0 75 6g Unloader Cap 62 71 In Lbs 7 8 Nm M8x1 25 6g Governor Adapter 195 213 In Los 22 24 Nm M8x1 25 6g Rear End Cover 195 213 In Lbs 22 24 Nm M6x1 00 6g Crankcase Cover 62 71 In Lbs 7 8 Nm M20x2 50 6g Crankshaft Nut 1858 2567 In Lbs 210 290 Nm Inlet Port Fittings 1 3 16 12 UN 2B seese 575 637 In Lbs 65 72 Nm MAT CZ nacenenie 575 637 In Lbs 65 72 Nm Discharge Port Fittings 118 14 UNF 2B soeren 460 504 In Lbs 52 57 Nm UPAS E E A E 195 213 In Lbs 22 24 Nm Water Port Fittings 3 4 16 UNF 2B ccn 319 245 In M18 X L5 Ororen 230 257 In Unloader Port Fittings OZNE T e asset ota sates desaaennae M10 X 1D Gerisini 120 145 In Safety Valve Port MIGOX L5 arnore 230 257 In 3 4 16 UNF 2B irisssnirinisiriisrini 319 345 In Dio UNF 2A srsisiinininaias 319 345 In UNP Te E Oil Port TING 20 UNF neen 97 115 In M12 X1 DGG 142 159 In Note TFFT Turns From Finger Tight Lbs 36 39 Nm Lbs 26 29 Nm ore 223 TFET Lbs 14 16 Nm Lbs 26 29 Nm Lbs 36 39 Nm Lbs 36 39 Nm baie 223 IF EE Lbs 11 13 Nm Lbs 16 18 Nm Advanced Troubleshooting Guide for Air Brake Compressors
63. undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer The typical size of a vehicle s discharge line see column 2 of Table A on page 13 assumes a compressor with a normal less than 25 duty cycle operating in a temperate climate See Bendix and or other air dryer manufacturer guidelines as needed When the temperature of the compressed air that enters the air dryer is within the normal range the air dryer can remove most ofthe charging system oil Ifthe temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 see pages 30 32 Shorter discharge line lengths or insulation may be required in cold climates
64. vanced Troubleshooting Guide forAir Brake Compressors starting on page 11 of this document to assist your investigation of the cause s Note All new vehicles are certified using the FMVSS 121 test paragraph 5 1 1 by the vehicle manufacturer however the above test is a useful guide for in service vehicles Optional Comparative Performance Check It may be useful to also conduct the above test with the engine running at high idle instead of maximum governed Speed and record the time taken to raise the system pressure a selected range for example from 90 to 120 psi or from 100 to 120 psi etc and record it in the vehicle s maintenance files Subsequent build up times throughout the vehicle s service life can then be compared to the first one recorded Note the 40 second guide in the test above does not apply to this build up time If the performance degrades significantly over time you may use the Advanced Troubleshooting Guide for Air Brake Compressors starting on page 11 of this document to assist your investigation of the cause s Note When comparing build up times be sure to make an allowance for any air system modifications which could cause longer times such as adding air components or reservoirs Always check for air system leakage LEAKAGE TESTS See the standard Air Brake System and Accessory Leakage test on Page 24 Test 2 Note Leakage in the air supply system components before the supply reser
65. voir such as the governor air dryer reservoir drain cocks safety valve and check valves will not be registered on the vehicle dash gauges and must be tested separately Refer to the various maintenance manuals for individual component leakage tests and the Bendix Test and Checklist published in the Air Brake System Handbook BW5057 and on the back of the Dual Circuit Brake System Troubleshooting card BW1396 Cylinder Head Check for cylinder head gasket air leakage 1 With the engine running lower air system pressure to 60 psi and apply a soap solution around the cylinder head Check the gasket between the cylinder head and valve plate assembly and the reed valve gasket between the valve plate assembly and cylinder block for air leakage 2 No leakage is permitted If leakage is detected replace the compressor or repair the cylinder head using a genuine Bendix maintenance kit available from an authorized Bendix parts outlets Inlet Discharge amp Unloader In order to test the inlet and discharge valves and the unloader piston itis necessary to have shop air pressure and an assortment of fittings A soap solution is also required 1 With the engine shut off drain ALL air pressure from the vehicle 2 Disconnect the inlet and discharge lines and remove the governor or its line or adapter fitting 3 Apply 120 130 psi shop air pressure to the unloader port and soap the inlet port Leakage at the inlet port Sho
66. weepage at the head gasket does not prevent the compressor from building air Observe the amount of weepage from the head gasket If the oil is only around the cylinder head area itis acceptable return the vehicle to service but if the oil weepage extends down to the nameplate area of the compressor the gasket can be replaced Test 2 Air Brake System and Accessory Leakage Inspect for air leaks when working ona vehicle and pedal in position Observe the dash gauges repair them promptly If you see any noticeable decrease of the dash air Park the vehicle on level ground and chock wheels gauge readings i e more than 4 psi plus two psi for Build system pressure to governor cut outand allow each additional trailer during either two minute test the pressure to stabilize for one minute repair the leaks and repeat this test to confirm that Step 1 Observe the dash gauges fortwo additional they have been repaired minutes without the service brakes applied Air leaks can also be found in the charging system Step 2 Apply the service brakes and allow the parking brakes and or other components inspect pressure to stabilize Continue holding for two and repair as necessary minutes you may use a block of wood to hold the Test 3 Air Compressor Discharge Temperature and Air Dryer Inlet Note that only vehicles that have passed Test 2 Temperature would be candidates for this test Caution The temperatures used in this test

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